Container with attached shelf

ABSTRACT

The opposed shelf flaps provide load bearing support to the main shelf panel and the main shelf panel is sufficiently rigid to support the weight of an upper product placed in the upper interior space in a manner such that an air gap is maintained between the top of a lower product placed into the lower interior space and the shelf itself so as to avoid unwanted contact between the two products.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates to containers, and more particularly to containers with compartments.

2. Description of Related Art

Various containers are provided for transporting or shipping goods. In some instances, the goods being transported are relatively fragile, e.g., baked goods and should not be impacted or pressed upon. Typically, goods like cakes are therefore packaged individually in containers strong enough to protect the cake inside during transport.

The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved transport or shipping containers. This disclosure provides a solution for this need.

SUMMARY OF THE INVENTION

A container comprises a plurality of panels connected together to enclose an interior space. The interior space is divided into an upper interior space and a lower interior space by a shelf adhered to one or more of the plurality of panels. The shelf includes a main shelf panel and a pair of opposed side shelf flaps connected to the main shelf panel along a pair of fold lines.

The shelf can extend from a first end of the interior space to an opposite end of the interior space along a longitudinal axis of the container. The pair of opposed shelf flaps can provide load bearing support to the main shelf panel, wherein the opposed shelf flaps are folded 90 degrees with respect to the main shelf panel. The main shelf panel can be sufficiently rigid to support the weight of an upper product that can be placed in the upper interior space in a manner such that an air gap can be maintained between the top of a lower product that can be placed into the lower interior space and the main shelf panel.

The shelf can include a pair of opposed shelf end flaps connected to the main shelf panel along a second pair of fold lines. One or more of the opposed shelf flaps or opposed shelf end flaps can be adhered to the plurality of panels and the main shelf panel can be not directly adhered to the plurality of panels. The shelf can include corrugated paper material.

The plurality of panels can include four panels, which, together with a plurality of flaps foldably connected to the plurality of panels, can connect together to form a rectangular footprint of the interior space. The plurality of panels can include eight panels, which, together with a plurality of flaps foldably connected to the plurality of panels can connect together to form an octagonal footprint of the interior space. The main shelf panel can be dimensioned to have the same dimensions as the footprint of the interior space.

A blank system for forming a container comprises a main blank includes a plurality of panels foldably connected together configured to enclose an interior space. The blank system includes a shelf blank which includes a main shelf panel and a pair of opposed side shelf flaps connected to the main shelf panel along a pair of fold lines. The shelf blank is configured to form a shelf in the interior space when adhered to the main blank and divide the interior space into an upper interior space and a lower interior space.

The shelf can be sized to extend from a first end of the interior space to an opposite end of the interior space along a longitudinal axis of the container. The pair of opposed shelf flaps can be configured to provide load bearing support to the main shelf panel, wherein the opposed shelf flaps are folded 90 degrees with respect to the main shelf panel.

The shelf blank can include a pair of opposed shelf end flaps connected to the main shelf panel along a second pair of fold lines. One or more of the opposed shelf flaps or opposed shelf end flaps can be adhered to the main blank and the main shelf panel itself need not be directly adhered to the main blank. The shelf blank can include corrugated paper material.

The main blank can be a first main blank, and the shelf blank can be a first shelf blank, wherein a plurality of main blanks like the first main blank and a plurality of shelf blanks like the first shelf blank can all be palletized. The main blanks can be palletized on one pallet, and the shelf blanks can be palletized on a separate pallet. The main blanks and shelf blanks can be palletized on a single pallet together. Each shelf blank can be adhered to a respective one of the main blanks before the blanks are palletized.

A method for forming a container includes joining a shelf blank onto a main blank, folding the main blank around an interior space, and folding the shelf blank into the interior space to create a shelf dividing the interior space into an upper interior space and a lower interior space. The method can include folding a plurality of flaps of the main blank to create a bottom of the container. The method can include placing a product into the lower interior space before the shelf blank is folded into place to form the upper interior space. The method can include placing a second product into the upper interior space on top of the shelf blank.

These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIGS. 1-2 are plan views of an embodiment of a blank system constructed in accordance with the present disclosure, showing the main blank and the shelf blank, respectively;

FIGS. 3-4 are plan views of another embodiment of a blank system constructed in accordance with the present disclosure, showing another main blank and another shelf blank, respectively;

FIGS. 5-12 are perspective views of the container of FIGS. 1-2, showing stages of erecting the blanks into a container;

FIG. 13 is a side view of the container of FIGS. 1-2, showing the container partially erected, viewing into the interior space of the container, with the shelf assembled therein;

FIGS. 14-23 are perspective views of the container of FIGS. 3-4, showing stages of erecting the blanks into a container;

FIG. 24 is a side view of the container of FIGS. 3-4 showing the container partially erected, viewing into the interior space of the container, with the shelf assembled therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a view of an embodiment of a blank system for forming a container in accordance with the disclosure is shown in FIGS. 1 and 2, and is designated generally by reference character 10. Other embodiments of containers in accordance with the disclosure, or aspects thereof, are provided in FIGS. 2-24 as will be described. The systems and methods described herein can be used to provide containers with attached dividers.

The blank system 10, depicted in FIGS. 1 and 2, includes a main blank 100 including a plurality of panels 102, 104, 106, 108 foldably connected together across respective fold lines 146, 148, 150 to enclose an interior space 152 (not visible in FIG. 1, but see FIG. 9). The main blank 100 also includes upper flaps 110, 112, 114, 116 and lower flaps 118, 120, 122, 124 foldably connected to each of the panels 102, 104, 106, 108, respectively. The upper flaps 110, 112, 114, 116 are foldably connected to the panels 102, 104, 106, 108 across respective fold lines 128, 132, 136, 140. The lower flaps 118, 120, 122, 124 are foldably connected to the panels 102, 104, 106, 108 across respective fold lines 130, 134, 138, 142. Each of the upper 110, 112, 114, 116 and lower 118, 120, 122, 124 flaps can be of similar size and shape from its respective opposite flap attached to the same panel. The upper 110, 112, 114, 116 and lower 118, 120, 122, 124 flaps can also differ in size and shape from its respective opposite flap attached to the same panel. The main blank 100 also includes a tab 126 foldably connected across fold line 144 to one of the plurality of panels 102.

The blank system 10 includes a shelf blank 200 which includes a main shelf panel 202 and a pair of opposed side shelf flaps 204, 206 foldably connected to the main shelf panel across respective fold lines 203, 205.

With reference now to FIG. 5, the shelf blank 200 is positioned over the main blank 100 on top of one of the plurality of panels 104 and one of the opposed flaps 112. The outer portion of the side shelf flap 206 aligns with fold line 134 between panel 104 and flap 120, so that the flap 120 can later fold at fold line 134 without interference from the shelf blank 200. The shelf blank 200 can be adhered to the main blank 100. The main blank 100 and shelf blank 200 can be composed of a paperboard or cardboard material which can be corrugated paper material.

With reference now to FIGS. 6-9, the folding of the plurality of panels 102, 104, 106, 108 across fold lines 142, 144, 146, 148 so as to enclose the interior space 152 (depicted in FIG. 9) is depicted. FIG. 6 depicts the tab 126 folding across fold line 144. As depicted in FIG. 7, the panels 102, 104, 106, 108 fold in a manner that brings the panel 108 into contact with the tab 126. The tab 126 can be adhered to the panel 108. FIG. 8 depicts the container 154 in a partially erected state, with flaps 120, 124 closed to partially form the bottom 123 of the container 154. Also visible in FIG. 8 are portions 202, 204 of the shelf blank 200 connected to the main blank 100. FIG. 9 depicts the partially erected container 154 with flaps 118, 122 folded closed to complete the bottom 123 of the container 154. As depicted in FIG. 9, the side shelf flap 204 folds 90° across fold line 203 with respect to the main shelf panel 202.

With reference to FIG. 10, the container 154 is shown with the shelf 207 folded into so as to create a lower interior space 156 (depicted in FIG. 13) within the interior space 152. The shelf 207 is formed by the folding of each of the opposed side shelf flaps 204, 206 across fold lines 203, 205 to 90° with respect to the main shelf panel 202. The opposed side shelf flaps 204, 206 can fold simultaneously or sequentially. The opposed side shelf flaps 204, 206 can fold to an acute angle with respect to the main shelf panel 202 during an intermediate phase of the folding process.

With reference to FIGS. 11 and 12, the top 125 of the container 154 is shown being formed by the folding closure of flaps 110, 114 (FIG. 11) and the folding closure of flaps 112, 116 (FIG. 12). The closure of the flaps 110, 114, 112, 116 to create the top 125 of the container 154 also creates an upper interior space 158 within the interior space 152 of the container 154. FIG. 12 depicts the erected, closed container 154. The container 154, and the interior space 152 display a rectangular footprint.

FIG. 13 depicts the container 154 partially erected to display a cross-sectional view of the container 154. Visible in FIG. 13 is the erected shelf 207, dividing the interior space 152 into a lower interior space 156 and an upper interior space 158. The shelf 207 spans the length of the interior space 152 along a longitudinal axis, L (depicted in FIG. 5). The shelf 207 also spans the width of the interior space 152 along a lateral axis, W (depicted in FIG. 5). The erected shelf 207 receives structural support from the folded opposed side shelf flaps 204, 206. The main shelf panel 202 serves as the area on which product can be placed. The main shelf panel 202 is supported by the folded side shelf flaps 204, 206 is of sufficient rigidity and strength to limit the amount of bowing into the lower interior space 156 when a load is applied thereto. The shelf 207 maintains an air gap between the top of the product in the lower interior space 156 and the portion of the main shelf panel 202 facing the lower interior space 156. The shelf blank 200 can be composed of a corrugated paper material, where the corrugations can be aligned to provide structural support and integrity for the assembled shelf 207. The weight of product loaded into the upper interior space 158, should be adequately supported so that no part of the shelf 207 deflects into the lower interior space 156 to touch, or otherwise impact a product placed into the lower interior space 156.

Without limiting the intended scope of potential uses for the disclosed container 154, an exemplary product that can be loaded into the disclosed container 154 is a cake, other baked goods, or other foods. Baked goods are relatively fragile products and will not transport in a satisfactory manner if force is applied to them, particularly from above. For example the disclosed container 154 can transport a cake in the lower interior space 156 without damaging it, even if the shelf 207 above the lower interior space 156 is supporting the weight of a separate cake in the upper interior space 158. In another example, a cake can be loaded into the lower interior space 156 while items related to the service of a cake such as utensils, plates, and cutlery can be loaded into the upper interior space 158 without the shelf 207 deflecting into the lower interior space 156 to impact the cake.

The main blank 100 can be a first main blank, and the shelf blank 200 can be a first shelf blank, where a plurality of main blanks 100 like the first main blank 100 and a plurality of shelf blanks 200 like the first shelf blank 200 are palletized for shipping. The main blanks 100 can be palletized on one pallet, and the shelf blanks 200 can be palletized on a separate pallet. The main blanks 100 and shelf blanks 200 can be palletized on a single pallet together. The main blanks 100 and shelf blanks 200 can be palletized together as depicted in FIG. 5, where each shelf blank 200 is positioned on a respective main blank 100. Each shelf blank 200 can be adhered to a respective main blank 100 before the blanks are palletized.

With reference now to FIGS. 3 and 4, another embodiment of a blank system 20 is shown, similar to the blank system 10 with respect to FIGS. 1-2 and 5-13. The blank system 20 incorporates the features of the blank system 10 discussed above, and some distinguishing features are described below.

The blank system 20 includes a main blank 300 and a shelf blank 400. The main blank 300 has 7 panels 302, 304, 306, 308, 310, 312, 314 which fold across respective fold lines 350, 352, 354, 356, 358, 360, 362. Two end flaps 301, 315 fold across respective fold lines 348, 362, and join together or adhere together to enclose an interior space 365 of a container 367. The end flaps 301, 315 can also be referred to synonymously as panels in the present disclosure. The shelf blank 400 is similar to the shelf blank 200 of the blank system 100, except that it has a pair of opposed shelf end flaps 408, 410 in addition to the pair of opposed side shelf flaps 404, 406.

With reference now to FIGS. 14-18, the folding of the plurality of panels 302, 304, 306, 308, 301, 312, 314 across respective fold lines 350, 352, 354, 356, 358, 360, 362 and the folding of end flaps 301, 315 across fold lines 348, 362 is depicted. Visible in FIG. 17 are the flaps 324, 326, 328, 330 folded across fold lines 334, 338, 342, 346 to enclose the bottom 325 of the container 367. Visible in FIG. 18 is the partially erected container 367 around which the panels 302, 304, 306, 308, 310, 312, 314 and end flaps 301, 315 have partially enclosed an interior space 365. Also visible in FIG. 18 are portions 402, 404, 408, 410 of the shelf blank 400 connected to the main blank 300.

With reference now to FIGS. 19 and 20, the folding of one of the opposed side shelf flaps 404 is shown. The side shelf flap 404 folds to an acute angle with respect to the main shelf panel 402 across fold line 405 to provide clearance between the main shelf panel 402 and the main blank panel 314 when the main shelf panel 402 is folded across fold line 409 to form the shelf 411. The folding of the main shelf panel 402 occurs sequentially in FIG. 21, and the result of the folding of the main shelf panel 402 to form the shelf 411 is depicted in FIG. 24. Similar to the erecting of the container 154 of the blank system 10, the folding of the shelf blank 400 to form the shelf 411 creates a lower interior space 368 in the interior space 365 of the container 367.

With reference now to FIGS. 21-23, the top 327 of the container 367 is formed by the folding of flaps 316, 318, 320, 322 across respective fold lines 332, 336, 340, 344. The folding of flaps 316, 318, 320, 322 to create the top 327 of the container 367 also creates an upper interior space 370 within the interior space 365 of the container 367. FIG. 23 depicts the erected, closed container 367. The container 367, and the interior space 365 adopt an octagonal footprint in this embodiment.

FIG. 24 presents, as depicted in FIG. 13, a cross-sectional view of the partially erected container 367. The features of the shelf 207 of the blank system 10 are shared with the shelf 411 formed within the container 367 formed by the blank system 20. The shelf 411 has opposed shelf end flaps 408, 410 which are contoured to fit closely to the shape created by the panels 308, 310, 312. When the container 367 is not opened as in FIG. 13, the shelf end flaps 408, 410 also fit closely with the shape created by the panels 302, 304 and joined end flaps 301, 315.

The methods and systems of the present disclosure, as described above and shown in the drawings, provide for containers with an interior divider. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure. 

1. A container comprising: a plurality of panels connected together to enclose an interior space, wherein the interior space is divided into an upper interior space and a lower interior space by a shelf adhered to one or more of the plurality of panels, wherein the shelf includes: a main shelf panel and a pair of opposed side shelf flaps connected to the main shelf panel along a pair of fold lines.
 2. The container as recited in claim 1, wherein the shelf extends from a first end of the interior space to an opposite end of the interior space along a longitudinal axis of the container.
 3. The container as recited in claim 1, wherein the pair of opposed shelf flaps provide load bearing support to the main shelf panel and wherein they are folded 90 degrees with respect to the main shelf panel.
 4. The container as recited in claim 3, wherein the main shelf panel is sufficiently rigid so as to support the weight of an upper product placed in the upper interior space in a manner that maintains an air gap between the top of a lower product placed into the lower interior space and the main shelf panel.
 5. The container as recited in claim 1, wherein the shelf includes a pair of opposed shelf end flaps connected to the main shelf panel along a second pair of fold lines.
 6. The container as recited in claim 5, wherein one or more of the opposed shelf flaps or opposed shelf end flaps is adhered to the plurality of panels and the main shelf panel is not directly adhered to the plurality of panels.
 7. The container as recited in claim 1, wherein the shelf includes corrugated paper material.
 8. The container as recited in claim 1, wherein the plurality of panels includes four panels, which, together with a plurality of flaps foldably connected to the plurality of panels, connect together to form a rectangular footprint of the interior space.
 9. The container as recited in claim 1, wherein the plurality of panels includes eight panels, which, together with a plurality of flaps foldably connected to the plurality of panels connect together to form an octagonal footprint of the interior space.
 10. The container as recited in claim 1, wherein the main shelf panel is dimensioned to have the same dimensions as the footprint of the interior space.
 11. A blank system for forming a container comprising: a main blank including a plurality of panels foldably connected together configured to enclose an interior space; and a shelf blank including a main shelf panel and a pair of opposed side shelf flaps connected to the main shelf panel along a pair of fold lines, wherein the shelf blank is configured to form a shelf in the interior space when adhered to the main blank and divide the interior space into an upper interior space and a lower interior space.
 12. The system as recited in claim 11, wherein the shelf is sized to extend from a first end of the interior space to an opposite end of the interior space along a longitudinal axis of the container.
 13. The system as recited in claim 10, wherein the pair of opposed shelf flaps are configured to provide load bearing support to the main shelf panel when they are folded 90 degrees with respect to the main shelf panel.
 14. The system as recited in claim 10, wherein the shelf blank includes a pair of opposed shelf end flaps connected to the main shelf panel along a second pair of fold lines.
 15. The system as recited in claim 12, wherein one or more of the opposed shelf flaps or opposed shelf end flaps is adhered to the main blank and the main shelf panel is not directly adhered to the main blank.
 16. The system as recited in claim 12, wherein the shelf blank includes corrugated paper material.
 17. The system wherein the main blank is a first main blank, and the shelf blank is a first shelf blank, further comprising a plurality of main blanks like the first main blank and a plurality of shelf blanks like the first shelf blank, wherein all the blanks are palletized.
 18. The system recited in claim 17, wherein the main blanks are palletized on one pallet, and wherein the shelf blanks are palletized on a separate pallet.
 19. The system recited in claim 17, wherein the main blanks and shelf blanks are palletized on a single pallet together.
 20. The system recited in claim 19, wherein each shelf blank is adhered to a respective one of the main blanks before the blanks are palletized.
 21. A method for forming a container comprising joining a shelf blank onto a main blank; folding the main blank around an interior space; folding the shelf blank into the interior space to create a shelf dividing the interior space into an upper interior space and a lower interior space.
 22. The method as recited in claim 18, further comprising folding a plurality of flaps of the main blank to create a bottom of the container, then placing a product into the lower interior space before folding the shelf blank into place to form the upper interior space.
 23. The method as recited in claim 22, further comprising placing a second product into the upper interior space on top of the shelf blank. 